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The effects of local variations in mechanical behaviour – Numerical investigation of a ductile iron component
Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.ORCID iD: 0000-0003-2671-9825
Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.
2012 (English)In: Materials & design, ISSN 0264-1275, Vol. 43, 264-271 p.Article in journal (Refereed) Published
Abstract [en]

The effects of incorporating local mechanical behaviour into a structural analysis of a cast ductile iron component are investigated. A recently presented simulation strategy, the closed chain of simulations for cast components, is applied to incorporate local behaviour predicted by a casting process simulation into a Finite Element Method (FEM) structural analysis, and the effects of the strategy on predicted component behaviour and simulation time are evaluated. The results are compared to using a homogeneous material description. A material reduction method is investigated, and the effects of material reduction and number of linearization points are evaluated.

The results show that local mechanical behaviour may significantly affect the predicted behaviour of the component, and a homogeneous material description fails to express the stress-strain distribution caused by the local variations in mechanical behaviour in the component. The material reduction method is able to accurately describe this effect while only slightly increasing the simulation time. It is proposed that local variations in mechanical behaviour are important to consider in structural analyses of the mechanical behaviour of ductile iron components.

Place, publisher, year, edition, pages
2012. Vol. 43, 264-271 p.
Keyword [en]
Casting, Component behaviour, Ductile iron, Mechanical behaviour, Plastic behaviour
National Category
Mechanical Engineering Metallurgy and Metallic Materials
Identifiers
URN: urn:nbn:se:hj:diva-19110DOI: 10.1016/j.matdes.2012.07.006OAI: oai:DiVA.org:hj-19110DiVA: diva2:543001
Projects
CompCAST
Available from: 2012-08-06 Created: 2012-08-06 Last updated: 2017-08-14Bibliographically approved
In thesis
1. Microstructure-based Mechanical Behaviour in Structural Analyses of Cast Components
Open this publication in new window or tab >>Microstructure-based Mechanical Behaviour in Structural Analyses of Cast Components
2012 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

In the process of developing cast iron and cast aluminium components, the co-operation between product development and production is important. On the engineering level, this co-operation is limited already in the product development phase e.g. by the lack of established methods to consider the mechanical behaviour of the completed component.

This thesis aims to increase the possibilities for co-operation in the product realisation process between product development and production by enabling the use of predicted local mechanical behaviour in structural analyses of cast components. A literature review on existing simulation methods and a work on characterization of mechanical behaviour from microstructural features are performed to identify important knowledge gaps. A simulation strategy is formulated that is able to predict local mechanical behaviour throughout the entire component and incorporate the behaviour into a Finite Element Method (FEM) simulation of the structural behaviour of the component. In the simulation strategy, the component specific microstructure-based mechanical behaviour is predicted using a casting process simulation. A computer program is developed to create FEM material definitions that capture the local variations in mechanical behaviour throughout the component.

The relevance of the simulation strategy is demonstrated for a ductile iron component. It is found that the local variations in mechanical behaviour result in a stress-strain distribution in the component that a homogeneous material description fails to express. Residual stresses affect the mechanical behaviour at low loads. At higher loads, however, the accuracy of the simulation is determined by the local variations in mechanical behaviour. Using a material reduction technique, the local mechanical behaviour can be incorporated without increasing the FEM simulation time. 

Place, publisher, year, edition, pages
Jönköping: School of Engineering, Jönköping University, 2012. 42 p.
Series
JTH Dissertation Series, 1
Keyword
Component behaviour, Structural analysis, Mechanical behaviour, Casting process simulation, Finite element method simulation
National Category
Mechanical Engineering Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-19127 (URN)978-91-87289-01-9 (ISBN)
Presentation
2012-08-31, Jönköpings Tekniska Högskola, E1405 Gjuterisalen, Gjuterigatan 5, Jönköping, 10:00 (Swedish)
Opponent
Supervisors
Available from: 2012-08-09 Created: 2012-08-08 Last updated: 2016-01-18Bibliographically approved
2. Simulation of Microstructure-based Mechanical Behaviour of Cast Components
Open this publication in new window or tab >>Simulation of Microstructure-based Mechanical Behaviour of Cast Components
2014 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

In the process of developing cast iron and cast aluminium components, a high level of co-operation between product development and production is of great importance. From an engineering standpoint, this co-operation is limited early in the product development phase by e.g. a lack of established methods for the consideration of local variations in the mechanical behaviour of a finished component.

This thesis aims to increase the possibilities for co-operation between product development and production during the product realisation process by introducing and studying the use of predicted local mechanical behaviour in structural analyses of cast components. A literature review of existing simulation methods and a work on characterisation of mechanical behaviour from microstructural features have been performed to identify important knowledge gaps. A simulation strategy has been formulated which is able to predict local mechanical behaviour throughout the entire component, and to incorporate this into a Finite Element Method (FEM) simulation of the structural behaviour of the component. In the simulation strategy, componentspecific microstructure-based mechanical behaviour is predicted using a casting process simulation. A computer program was developed to create FEM material definitions which capture the local variations in mechanical behaviour throughout the component. Using a material reduction technique, the local mechanical behaviour can be incorporated without increasing the FEM simulation time.

The relevance of the simulation strategy was experimentally verified on cast aluminium samples, where the strain field was observed using Digital Image Correlation (DIC). It was found that the local variations in mechanical behaviour cause a stress-strain distribution that deviates from that predicted by a homogeneous material description, indicating the importance of calculating with and including such variations in material behaviour in FEM simulations. Numerical investigations demonstrate the strategy’s relevance for predicting the behaviour of cast aluminium and ductile iron components.

Place, publisher, year, edition, pages
School of Engineering, Jönköping University, 2014. 51 p.
Series
JTH Dissertation Series, 3
Keyword
Component behaviour, structural analysis, mechanical behaviour, casting process simulation, Finite Element Method (FEM) simulation
National Category
Metallurgy and Metallic Materials Applied Mechanics
Identifiers
urn:nbn:se:hj:diva-23695 (URN)978-91-87289-04-0 (ISBN)
Public defence
2014-05-09, E1405, Tekniska Högskolan, Gjuterigatan 5, Jönköping, 10:00 (English)
Opponent
Supervisors
Available from: 2014-04-14 Created: 2014-04-11 Last updated: 2014-04-14Bibliographically approved

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